525 kg Integral Forged Housing for a Turkish Engineering Company
- A Turkish engineering company required a customized 525 kg forged housing for heavy mechanical equipment.
- Because the component was large and structurally critical, the customer required an integrally forged structure without welding, together with strict dimensional tolerances, surface finish, and grain-size requirements.
Project Overview
The customer is a Turkish engineering company requiring a heavy-duty forged housing for mechanical equipment.
The component weighed approximately 525 kg and needed to be produced as a one-piece forging rather than a welded assembly. After forging, multiple critical surfaces and interfaces required precision machining to meet the customer’s drawing specifications.
The project requirements included:
- Product: Custom forged housing
- Finished Weight: Approx. 525 kg
- Application: Heavy mechanical equipment
- Manufacturing Process:Integral Forging + Heat Treatment + Precision Machining
- Construction: One-piece forged structure
- Welding: Not permitted
- Critical Tolerance:±0.05 mm
- Surface Roughness:Ra ≤ 3.2 μm
- Key Requirement:Dimensional stability and structural integrity
- Grain Size Requirement:Grade 8
The project Challenge:
The main challenge was producing such a large housing as a single forging while still maintaining the machining accuracy and metallurgical quality required for the final component.
Project Challenge
Challenge 1 : Producing a 525 kg Housing Without Welded Construction
Due to the size and geometry of the housing, welded fabrication would normally simplify manufacturing.
However, the customer specifically required a one-piece forged structure to avoid welded joints and maintain continuous material integrity throughout the component.
This increased the difficulty of controlling:
- Forging deformation
- Material flow
- Section thickness consistency
- Internal structural uniformity
- Residual stress
- Overall dimensional stability
Our Solution: Integral Forging With Controlled Deformation
The housing was produced from a single forged blank, with the forging sequence designed around the final geometry and machining allowance.
- The manufacturing process focused on:
- One-piece forging without welding
- Controlled forging deformation
- Optimized material flow
- Sufficient machining allowance
- Uniform heat treatment
- Residual stress control
- Dimensional verification before machining
This approach maintained structural continuity while providing enough material for subsequent precision machining.
Challenge 2 : Maintaining Tight Tolerances and Surface Quality on a Large Component
Large forged housings can experience dimensional variation after forging and heat treatment, making tight machining tolerances difficult to maintain.
For this project, the customer required critical dimensions within ±0.05 mm, surface roughness of Ra 3.2 μm or better, and a grain-size rating of 8.
The large size and weight of the workpiece also increased the difficulty of setup, datum control, and machining stability.
Our Solution: Precision Machining and Multi-stage Inspection
After forging and heat treatment, the housing underwent precision machining with careful control of machining sequence, datum positioning, and finishing allowance.
- Key controls included:
- Stable datum establishment
- Rough and finish machining in separate stages
- Machining allowance optimization
- Critical-dimension inspection
- Surface roughness verification
- Dimensional checks after finishing
- Final comparison with customer drawings
By combining controlled forging with precision machining, dimensional variation was reduced beyond the customer’s original requirement.
Projest Results
The Result: Improved Accuracy and Surface Finish
The completed forged housing exceeded the customer’s original technical requirements.The final component provided the required structural integrity, machining accuracy, and surface quality while maintaining a fully forged one-piece construction.
- Final inspection results included:
- Critical Tolerance: ±0.02 mm
- Surface Roughness: Ra 1.6 μm
- Grain Size: Grade 8.5
- Construction: Integral forged structure without welding
- Dimensional Result: Finished dimensions matched the customer’s drawings
The project demonstrated strong capability in manufacturing large, heavy forged housings with tight dimensional tolerances and demanding metallurgical requirements.